Multizone recreational cooler

ABSTRACT

A cooler includes a body. The cooler also includes a divider that divides an interior of the body into a first zone and a second zone. A first phase change material module is disposed in the first zone of the interior of the body and a second phase change material module is disposed in the second zone of the interior of the body.

BACKGROUND

Temperature sensitive goods and products may sometimes be transported away from active sources of temperature regulation such as refrigerators or freezers. When transported away from the active sources of temperature regulation, exposure to an ambient environment may cause the temperature of the temperature sensitive goods or products to change. Changing of the temperature of the temperature sensitive goods may degrade a quality or other characteristics of the temperature sensitive goods or products.

SUMMARY

In one aspect, a cooler in accordance with one or more embodiments of the invention includes a body, a divider that divides an interior of the body into a first zone and a second zone, a first phase change material module disposed in the first zone, and a second phase change material module disposed in the second zone.

In one aspect, a method of assembling a cooler in accordance with one or more embodiments of the invention includes obtaining thermal information of goods to be disposed in the cooler; determining, based on at least in part the thermal information, a quantity of zones; determining, based on at least in part the thermal information of a portion of the goods to be disposed in a first zone of the quantity of zones, a type and a quantity of phase change material modules; dividing, based on the quantity of zones, the cooler into the quantity of zones by inserting dividers; loading, based on portion of the goods to be disposed in the first zone and the quantity and type of phase change material modules, the portion of the goods and the quantity and the type of phase change material modules into the first zone.

In one aspect, a cooler in accordance with one or more embodiments of the invention includes a body, a first divider that includes a first phase change material module that divides an interior of the body into a first zone and a second zone, and a second phase change material module disposed in the second zone.

BRIEF DESCRIPTION OF DRAWINGS

Certain embodiments of the invention will be described with reference to the accompanying drawings. However, the accompanying drawings illustrate only certain aspects or implementations of the invention by way of example and are not meant to limit the scope of the claims.

FIG. 1 shows a diagram of an isometric view of a cooler in accordance with one or more embodiments of the invention.

FIG. 2 shows a diagram of a side view of a first example of a configuration of a cooler in accordance with one or more embodiments of the invention.

FIG. 3 shows a diagram of a side view of a second example of a configuration of a cooler in accordance with one or more embodiments of the invention.

FIG. 4 shows a diagram of a side view of a third example of a configuration of a cooler in accordance with one or more embodiments of the invention.

FIG. 5 shows a diagram of a side view of a fourth example of a configuration of a cooler in accordance with one or more embodiments of the invention.

FIG. 6A shows a diagram of a top view of a phase change material (PCM) module in accordance with one or more embodiments of the invention.

FIG. 6B shows a diagram of a side view of a phase change material (PCM) module in accordance with one or more embodiments of the invention.

FIG. 7 shows a diagram of a side view of goods and phase change material (PCM) modules in accordance with one or more embodiments of the invention.

FIG. 8 shows a diagram of a side view of a fifth example of a configuration of a cooler in accordance with one or more embodiments of the invention.

FIG. 9 shows a flow chart of a method of assembling a cooler in accordance with one or more embodiments of the invention.

DETAILED DESCRIPTION

Specific embodiments will now be described with reference to the accompanying figures. In the following description, numerous details are set forth as examples of the invention. It will be understood by those skilled in the art that one or more embodiments of the present invention may be practiced without these specific details and that numerous variations or modifications may be possible without departing from the scope of the invention. Certain details known to those of ordinary skill in the art are omitted to avoid obscuring the description.

In general, embodiments of the invention relate to devices, systems, and/or methods for temperature control. A device in accordance with one or more embodiments of the invention may be a cooler. The cooler may regulate a temperature of goods disposed within the cooler. The goods may be, for example, beer, wine, dairy products, and/or produce.

In one or more embodiments of the invention, the cooler may include multiple zones. Each zone may regulate the temperature of goods disposed within the zone at a temperature. Two zones may regulate the temperature of the goods disposed in each respective zone at different temperatures. For example, the cooler may include a first zone that regulates the temperature of goods disposed in the first zone at 25° Fahrenheit and the cooler may include a second zone that regulates the temperature of goods disposed in the second goods at 35° Fahrenheit.

In one or more embodiments of the invention, the cooler may include a single zone. The single zone may regulate the temperature of goods disposed within the zone at a desired temperature.

The cooler may include an interior region and one or more dividers. Each of the dividers may be independently configured to subdivide the interior region into zones. The dividers may be insulated and thereby thermally isolate each zone within the interior region from the other zones. In one or more embodiments of the invention, the cooler may not include any dividers and thereby include a single zone in the interior region.

The cooler may include a number of phase change material (PCM) modules. A first portion of the PCM modules may be disposed in a first zone of the cooler and have a first phase transition temperature and a second portion of the PCM modules may be disposed in a second zone of the cooler and have a second phase transition temperature. The first and second phase transition temperatures may be different.

In one or more embodiments of the invention, a PCM module may have a shape complimentary to that of a good. For example, a PCM module may have a shape including an embossment in the shape of an end of a can of beer.

Additional embodiments may relate to a method of maintaining the temperature of goods. The method may include determining a number of portions of the goods having separate temperature profiles. Based on the number of portions of the goods, dividers of a cooler may be used to generate a number of zones within the cooler proportional to the number of portions of the goods. Based on the number of portions and temperature profile of each portion, a number of sets of PCM modules proportional to the number of portions of goods may be determined. Each set may have a phase change transition temperature of the temperature portion of the corresponding portion of the goods. Each set of PCM modules may be chilled below the phase change temperature of each set and placed within a separate zone of the cooler. Each portion of the goods may be placed in a zone of the cooler having a set of PCM modules with a phase change transition temperature corresponding to the temperature profile of the portion goods.

FIG. 1 shows a diagram of an isometric view of a cooler (100) in accordance with one or more embodiments of the invention. The cooler (100) may include a body (110), a lid (120), one or more latches (130), a drain valve (140), one or more feet (150), one or more dividers (160), and one or more set of PCM modules. Each of the components of the cooler (100) is described below.

The body (110) may be a hollow, thermally insulated structure formed from roto-molded plastic. The body (110) may have a shape of, for example, a rectangular prism. The body (110) may have other shapes without departing from the invention. The body (110) may include one open side through which goods may be placed into the hollow portion of the body (110).

The body (110) may include a layer of polyurethane foam encapsulated by a layer of food-grade linear low-density polyethylene. In one or more embodiments of the invention, the polyurethane foam may have a thickness of two inches. The encapsulating layer may be non-toxic, eco-friendly, and ultra violet ray degradation resistant. In one or more embodiments of the invention, the body may have an interior volume of 30 liters. In one or more embodiments of the invention, the body may have an interior volume of 50 liters. In one or more embodiments of the invention, the body may have an interior volume of 80 liters. In one or more embodiments of the invention, the body may have an interior volume of 120 liters.

The cooler (100) may include a lid (120) configured to reversibly close/seal the open side of the body (110). The lid (120) may have a shape that is complimentary to the shape of the open side of the body (110). The lid (120) may be connected to the body (110) by a rotation joint. The location of the rotational joint may align the lid (120) with the opening of the body (110) when the lid (120) is rotated to a closed position and thereby create a seal between the lid (120) and the body (110). When rotated to an open position, the lid (120) may not be aligned with the opening of the body (120) and thereby allow goods, dividers (160), PCM modules (170), and/or other items to be placed into or removed from the interior of the body (110).

The lid (120) may include a layer of polyurethane foam encapsulated by a layer of food-grade linear low-density polyethylene. In one or more embodiments of the invention, the polyurethane foam of the lid may have a thickness of two inches. The encapsulating layer may be non-toxic, eco-friendly, and ultra violet ray degradation resistant.

In one or more embodiments of the invention, the lid (120) may include an interlocking portion (121). The interlocking portion (121) may increase the sealing area between the lid (120) and the body (110) when the lid (120) is in the closed position. The interlocking portion (121) may be, for example, a raised portion of the lid (120). The raised portion may extend into the interior of the body (110) when the lid (120) is in a closed position and thereby generate a larger area of surface contact between the lid (120) and the body (110). The larger area of surface contact may improve the seal between the body (110) and the lid (120) and thereby improve the thermal insulating properties of the cooler (100). In one or more embodiments of the invention, the interlocking portion (121) may extend an inch or more into the interior of the body (110).

In one or more embodiments of the invention, a gasket (122) may be disposed along an interface surface of the lid (120) or the body (110). The gasket (122) may be a foam material that creates a thermal seal between the lid (120) and the body (110) when the lid is in the closed position. The gasket (122) may be other materials without departing from the invention.

The cooler (100) may include one or more latches (130). The latches (130) may be configured to fixedly hold the lid (120) in the closed position. The latches (130) may include a first attachment portion disposed on the body (110) and a second attachment portion disposed on the lid (120). The latches (130) may include a release mechanism that may be actuated to release a connection between the first and second attachment portions and thereby enable the lid (120) to be opened. In one or more embodiments of the invention, the latches (130) may be rubber latches. One of ordinary skill in the art will appreciate that other structures such as ties, snaps, quick release mounts, or other structures could be used in place of the latches (130) without departing from the invention.

The cooler (100) may include a drain valve (140) disposed on the body (110). The drain valve may enable fluids to be drained from the interior of the body (110).

The cooler (100) may include one or more feet (150) disposed on a bottom surface of the body (110). The feet (150) may be made of a non-slip, non-marking rubber material. In one or more embodiments of the invention, the cooler (100) may include four feet. The cooler (100) may include other quantities of feet (150) without departing from the invention. One of ordinary skill in the art will appreciate that other structures such as wheels, bearings, casters, or other structures could be used in place of the feet (150) without departing from the invention.

The cooler (100) may include one or more dividers (160). The dividers (160) may be panels having a shape of a portion of the interior of the body (110). Some dividers (160) may have different shapes.

In one or more embodiments of the invention, the dividers (160) may be thermally insulated. The insulation may be polyurethane foam. For example, a divider (160) may be a rectangular panel including a layer of polyurethane foam encapsulated by a housing having a shape that conforms to apportion of the interior of the body (110). When placed in a cooler (100), the panel may divide at least a portion of the interior of the body (110) into multiple zones and thereby thermally insulate each of the zones from one another.

In one or more embodiments of the invention, the dividers (160) may include a PCM module, discussed below. The PCM module may be a container or housing that include phase change material disposed within the container or housing. The phase change material may have a solid-liquid phase change transition temperature. For example, a divider (160) may be a rectangular panel including a container that includes phase change material having a solid-liquid phase change transition temperature. The solid-liquid phase change transition temperature may be configured by adjusting the composition on the phase change material. When placed in a cooler (100), the rectangular panel may divide at least a portion of the interior of the body (110) into multiple zones. The solid-liquid phase change transition temperature may correspond to a desired regulation temperature of at least one of the zones generated by placing the panel within the body (110).

In one or more embodiments of the invention, the dividers (160) may include a PCM module and thermal insulation. The PCM module may be a container or housing that include phase change material disposed within the container or housing. The phase change material may have a solid-liquid phase change transition temperature. The insulation may be polyurethane foam. For example, a divider (160) may include a rectangular panel including a container that includes phase change material having a solid-liquid phase change transition temperature. The divider (160) may also include a layer of thermal insulation disposed on a side of the rectangular panel. When placed in a cooler (100), the rectangular panel may divide at least a portion of the interior of the body (110) into multiple zones. Each of the zones may be thermally insulated from each other zone by the thermal insulation. The PCM module may regulate a temperature of a zone to which the PCM module is adjacent, e.g., a zone not thermally isolated from the PCM module by the thermal insulation. The solid-liquid phase change transition temperature of the phase change material of the PCM module may correspond to a desired regulation temperature the zone to which the PCM module is adjacent.

One of ordinary skill in the art will appreciate that numerous variations regarding the relative placement of the thermal insulation and PCM module of a divider are possible without departing from the invention.

In one or more embodiments of the invention, the dividers (160) may include a bottle configured to receive a fluid. The fluid may be air, water, or phase change material. Depending on the desired configuration of the cooler, a user of the cooler may load the bottle with one of the aforementioned fluids to thermally isolate and/or thermally regulate goods disposed within the cooler. For example, a user may place a divider including a bottle that contains air to subdivide the interior of the cooler into two zones. The air disposed within the bottle of the divider may be a thermal insulator and thereby thermally isolate each of the subdivided regions of the interior of the cooler. In a second example, a user may place a divider including a bottle that contains water into a cooler to subdivide the interior of the cooler. In addition to subdividing the cooler, the divider may act as a cold water storage container and thereby enable a user of the cooler to store cold, potable water within the cooler while also subdividing the interior into multiple regions.

The dividers (160) may be configured to be placed within the interior of the body (110) and thereby generate zones (161). Each of the zones (161) may be thermally insulated from the other zones (161) by the dividers (160) and from an environment surrounding the cooler (100) by the body (110) and/or lid (120). Generation and use of zones (161) is discussed further with respect to FIGS. 2-5 and 8.

The cooler may include one or more sets of PCM modules (170). Each set of PCM modules (170) may be configured to regulate temperature. Each set of PCM modules may regulate temperate at a different temperature, e.g., a first set of PCM modules may regulate at 25° while a second set of PCM modules may regulate at a temperature of 33° Fahrenheit. Each PCM modules of a set of PCM modules may include a housing. The housing may be made of, for example, high density polyethylene. The housing may be other material without departing from the invention. The shape of the housing may be, for example, cylindrical, rectangular, or in the form of a panel. In one or more embodiments of the invention, the shape of the housing may be complimentary to a good. PCM modules having a complimentary shape are shown and described below with respect to FIGS. 6A-8. The housing may have other shapes without departing from the invention.

Each of the PCM modules of a set may include a quantity of phase change material having a solid-liquid phase change transition temperature. The solid-liquid phase change transition temperature set based on the regulation temperature of the set of PCM modules. The quantity and/or type of phase change material may be set based on the regulation temperature. In one or more embodiments of the invention, the phase change material may be water include a quantity of one or more salts. The quantity of one or more salts may be set, at least in part, on the quantity of water and the regulation temperature of the set of PCM modules. In one or more embodiments of the invention, each of the PCM modules may include 2-8 lbs of PCM.

Each set of PCM modules (170) may be placed into separate zones (161) of the body (110) and thereby regulate goods in each zone of the zones (161) at different temperatures. Regulation of the temperature of goods in each zone by the PCM modules is further described with respect to FIGS. 2-8.

By way of the configurability of the dividers (160) and sets of PCM modules (170) to generate zones that regulate goods within each zone at different temperatures, the cooler (100) may be configured in numerous variations. Various examples of configurations of the cooler (100) are shown in FIGS. 2-8.

FIG. 2 shows a diagram of a cross sectional view of an example configuration of a cooler in accordance with one or more embodiments of the invention. As seen from FIG. 2, the interior of the body (110) is divided by a divider (200) into a first zone (201) and a second zone (202). The divider (200) and body (110) are thermally insulated and thereby reduce the flow of heat between the first zone (201), the second zone (202), and an environment surrounding the cooler. In FIG. 2, the divider is vertically oriented and thereby generated two zones directly accessible through an opening in the body (110).

A first set of goods (210) and a first set of PCM modules (230) are disposed within the first zone (201). The first set of PCM modules (230) are cooled to a temperature below the solid-liquid phase transition temperature of the first set of PCM modules (230). When heat flows into the first zone (201), a portion of phase change material module absorbs the heat flow and undergoes a solid-liquid phase transition thereby regulates the temperature of the first zone (201) when the flow of heat would increase the temperature within the first zone (201) above the phase transition temperature. By undergoing a solid-liquid phase transition, the portion of the first set of PCM modules (230) maintains the temperature within the first zone (201) at the solid-liquid phase transition temperature of the first set of PCM modules (230).

Similarly, a second set of goods (220) and a second set of PCM modules (240) are disposed within the second zone (202). The second set of PCM modules (240) are cooled to a temperature below the solid-liquid phase transition temperature of the second set of PCM modules (240). When heat flows into the second zone (202), a portion of phase change material module absorbs the heat flow and undergoes a solid-liquid phase transition thereby regulating the temperature of the second zone (202) when the flow of heat would increase the temperature of the second zone (202) above the phase transition temperature. By undergoing a solid-liquid phase transition, the portion of the second set of PCM modules (240) maintains the temperature of the second zone (202) at the solid-liquid phase transition temperature of the second set of PCM modules (240).

Thus, by the configuration shown in FIG. 2, the first set of goods (210) may be maintained at the phase transition temperature of the first set of PCM modules (230) and the second set of goods (220) may be maintained at the phase transition temperature of the second set of PCM modules (240).

FIG. 3 shows a diagram of a cross sectional view of a second example configuration of a cooler in accordance with one or more embodiments of the invention. As seen from FIG. 3, the interior of the body (110) is divided by a first divider (300) and a second divider (301) into a first zone (305), second zone (306), and a third zone (307). The first and second dividers and body (110) are thermally insulated and thereby reduce the flow of heat between the first zone (305), the second zone (306), the third zone (307), and an environment surrounding the cooler. In FIG. 3, the dividers are vertically oriented and thereby generate three zones directly accessible through an opening in the body (110).

The first zone (305) includes a first set of PCM modules (310) having a first phase transition temperature and a first set of goods (311). The second zone (306) includes a second set of PCM modules (320) having a second phase transition temperature and a second set of goods (321). The third zone (307) includes a third set of PCM modules (330) having a third phase transition temperature and a third set of goods (331).

Thus, by the configuration shown in FIG. 3, the first set of goods (311) may be maintained at the phase transition temperature of the first set of PCM modules (310), the second set of goods (321) may be maintained at the phase transition temperature of the second set of PCM modules (320), and the third set of goods (331) may be maintained at the phase transition temperature of the third set of PCM modules (330).

FIG. 4 shows a diagram of a cross sectional view of a third example configuration of a cooler in accordance with one or more embodiments of the invention. As seen from FIG. 4, the interior of the body (110) is divided by a divider (400) into a first zone (405) and a second zone (406). The divider (400) and body (110) are thermally insulated and thereby reduce the flow of heat between the first zone (405), the second zone (406) and an environment surrounding the cooler. In FIG. 4, the divider (400) is horizontally oriented and thereby only the first zone (405) may be directly accessible by an opening in the body (110).

The first zone (405) includes a first set of PCM modules (410) having a first phase transition temperature and a first set of goods (411). The second zone (406) includes a second set of PCM modules (420) having a second phase transition temperature and a second set of goods (421).

Thus, by the configuration shown in FIG. 4, the first set of goods (411) may be maintained at the phase transition temperature of the first set of PCM modules (410) and the second set of goods (421) may be maintained at the phase transition temperature of the second set of PCM modules (420).

While horizontal and vertical dividers have been shown separately in FIGS. 2-4, horizontal and vertical dividers may be used together and thereby form zones. Additionally, each zone need not have an approximately equal size. FIG. 5 shows a diagram of a cross sectional view of a fourth example configuration of a cooler in accordance with one or more embodiments of the invention. As seen from FIG. 5, the interior of the body (110) is divided by a first divider (500) and a second divider (501) into a first zone (505), second zone (506), and a third zone (507). The first and second dividers and body (110) are thermally insulated and thereby reduce the flow of heat between the first zone (505), the second zone (506), the third zone (507), and an environment surrounding the cooler. In FIG. 5, the first divider (500) is vertically oriented and the second divider (501) is horizontally oriented and thereby generate two zones, e.g., first and second, directly accessible through an opening in the body (110) and one zone, e.g., the third zone, that is not directly accessible through the opening. Additionally, the first zone (505) has a larger size than the second zone (506) and the third zone (507).

The first zone (505) includes a first set of PCM modules (510) having a first phase transition temperature and a first set of goods (511). The second zone (506) includes a second set of PCM modules (520) having a second phase transition temperature and a second set of goods (521). The third zone (507) includes a third set of PCM modules (530) having a third phase transition temperature and a third set of goods (331).

Thus, by the configuration shown in FIG. 5, the first set of goods (511) may be maintained at the phase transition temperature of the first set of PCM modules (510), the second set of goods (521) may be maintained at the phase transition temperature of the second set of PCM modules (520), and the third set of goods (531) may be maintained at the phase transition temperature of the third set of PCM modules (530).

While the PCM modules shown in FIGS. 2-5 have been shown as having a rectangular shape, the PCM modules may have other shapes without departing from the invention.

FIG. 6A shows a diagram of a top view and FIG. 6B shows a side view diagram of an example of a PCM module in accordance with one or more embodiments of the invention. As seen from FIGS. 6A-6B, the PCM module includes a number of embossments (600). Each of the embossments (600) has a shape that is complementary to a shape of a good. By having a complementary shape, the contact area between a good and a PCM module may be increased when compared to PCM modules that do not include embossments or other features having a complementary shape of a good.

FIG. 7 shows a diagram of a side view of PCM modules (700) goods (700) disposed on PCM modules (705) having embossments (710) having a shape complementary to the shape of the goods (700). As seen from FIG. 7, the contact area between the goods (700) and PCM modules (705) is increased by the embossments (710).

While the example cooler configurations shown in FIGS. 2-5 have only included a single type of PCM module, cooler configurations may include multiple types of PCM modules without departing from the invention.

FIG. 8 shows a diagram of a cross sectional view of a sixth example configuration of a cooler including two types of PCM modules in accordance with one or more embodiments of the invention. As seen from FIG. 8, the interior of the body (110) is divided by a divider (800) into a first zone (805) and a second zone (806). The divider (800) and body (110) are thermally insulated and thereby reduce the flow of heat between the first zone (805), the second zone (806), and an environment surrounding the cooler.

The first zone (805) includes a first set of PCM modules (810) having a first phase transition temperature and a first set of goods (811). The second zone (806) includes a second set of PCM modules (820) having a shape that conforms to a shape of a second set of goods (421) disposed within the second zone (806).

Thus, by the configuration shown in FIG. 8, the first set of goods (811) may be maintained at the phase transition temperature of the first set of PCM modules (810) and the second set of goods (821) may be maintained at the phase transition temperature of the second set of PCM modules (820). Due to the larger contact area between the second set of goods (821) and the second set of PCM modules (820) the temperature of the second set of goods (821) may be more uniform than the temperature of the first set of goods (811).

In one or more embodiments of the invention, the cooler may include one or more temperature sensor modules. Each temperature sensor module may comprise a temperature sensor, a processor, and a wireless transceiver.

The temperature sensor may be, for example, a thermocouple. The temperature sensor may sense a temperature and provide an output indicating the temperature. The temperature sensor may be operatively coupled to the processor and thereby notify the processor of the temperature.

The processor may be, for example, a microcontroller or other digital logic device. The processor may be configured to monitor temperature readings received from the temperature sensor and generate an alert if the monitored temperature exceeds a predetermined value. The processor may be operatively coupled to the transceiver and thereby transmit the alert wirelessly.

The transceiver may be configured to transmit alerts received from the processor. The transceiver may be, for example, a 3G or cellular compatible transceiver, a WLAN compatible transceiver, a blue tooth compatible transceiver, or any other type of wireless transceiver.

Each of the temperature sensor modules may be disposed in one or more zones of the cooler and thereby monitor the temperature of the zones. The temperature sensor modules may alert a user of the cooler in the event a temperature of one of the zones exceeds the predetermined value of each temperature sensor module. For example, a user of the cooler may have a cellular phone, tablet computer, or any other type of portable computing appliance. The portable computing appliance may include a wireless transceiver compatible with the wireless transceivers of the temperature sensor modules and thereby may be operatively connected by a wireless link to the temperature sensor modules. If a temperature sensor module determines a temperature of one of the zones exceeds a predetermined temperature, the temperature sensor module may alert the portable communication appliance by the wireless link. The portable communication appliance may, in turn, alert the user by audio, tactile, and/or visual alerts.

FIG. 9 shows a flowchart in accordance with one or more embodiments of the invention. The method depicted in FIG. 9 may be used to configure a cooler in accordance with one or more embodiments of the invention. One or more steps shown in FIG. 9 may be omitted, repeated, and/or performed in a different order among different embodiments.

In Step 900, thermal information of goods to be disposed in a cooler is obtained. The thermal information may include a desired regulation temperature of each good.

In Step 910, a quantity of zones to be generated in the cooler is determined based the thermal information of the goods. The quantity of zones may be determined by separating the goods into groups based on the desired regulation temperate of each good. The quantity of zones may be the determined number of groups.

In Step 920, a type and/or quantity of PCM modules for each zone of the quantity of determined zones is determined based on the thermal information of the goods. The type of PCM modules for each zone may be determined based on the regulation temperature of a group of goods that is to be disposed in each zone, determined in Step 910. The quantity of PCM modules for each zone may be proportional to the quantity of goods of a group of goods to be disposed in each zone.

In Step 930, a cooler may be divided into zones based on the quantity of zones determined in Step 910. The zones may be generated by inserting dividers as shown, for example, in FIGS. 2-5 and 8. The volume of each zone may be set based on a quantity of goods of a group of goods to be disposed in each zone.

In Step 940, the group of goods to be disposed in each zone is placed in the associated zone and the PCM modules, determined in 920, associated with each zone is placed in each zone. The method may end after Step 940.

Thus, the method shown in FIG. 9 may be used, for example, to assemble a cooler by generating zones that regulate the temperature of goods disposed in each zone at different temperatures.

The following are examples of usages of a cooler in accordance with one or more embodiments of the invention. In each of the following examples, a cooler may include one or more phase change material modules and one or more dividers. The phase change material modules and/or dividers may vary in size, number, and shape in each example. The following examples are explanatory examples and not intended to limit the invention.

Example 1

A person may desire to keep ice cream frozen and lettuce chilled. Based on the thermal information of the ice cream and lettuce, a cooler including two zones of temperature regulation may be required. To generate the two zones, a divider may be placed in the cooler thereby forming a first zone and a second zone.

Based on the thermal information of the ice cream, e.g., frozen, a PCM module having a solid-liquid phase change temperature of 5° Fahrenheit may be selected. Based on the thermal information of lettuce, e.g., chilled, a second PCM modules having a solid-liquid phase change temperature of 35° Fahrenheit may be selected. The first PCM module may be chilled to 5° Fahrenheit and the second PCM module may be chilled to 35° Fahrenheit. Both PCM modules undergo, respective, liquid to solid phase transitions in response to being chilled.

Once chilled, the ice cream and the first PCM module may be placed in the first zone. The lettuce and the second PCM module may be placed in the second zone.

The cooler may then be exposed to an environment surrounding the cooler having a temperature of 55° Fahrenheit and thereby result in a flow of heat from the environment into the cooler. In response to the heat flow, the first PCM modules absorb the heat and a portion of the first PCM module undergoes a solid to liquid phase change and thereby maintains the temperature within the first zone at 5° Fahrenheit. Similarly, in response to the heat flow, the second PCM modules absorb the heat and a portion of the second PCM module undergoes a solid to liquid phase change and thereby maintains the temperature within the second zone at 35° Fahrenheit.

Example 2

A caterer may desire to transport frozen ribs and fresh carrots to an event. Based on the thermal information of the ribs and carrots, a cooler including two zones of temperature regulation may be required. To generate the two zones, a divider may be placed in the cooler thereby forming a first zone and a second zone.

Based on the thermal information of the ribs, e.g., frozen, and the quantity of ribs four PCM modules having a solid-liquid phase change temperature of 5° Fahrenheit may be selected. Based on the thermal information of carrots, e.g., chilled, and the quantity of carrots a fifth PCM modules having a solid-liquid phase change temperature of 40° Fahrenheit may be selected. The four PCM modules may be chilled to 5° Fahrenheit and the second PCM module may be chilled to 40° Fahrenheit. The PCM modules undergo, respective, liquid to solid phase transitions in response to being chilled.

Once chilled, the ribs and the four PCM modules may be placed in the first zone. The carrots and the fifth PCM module may be placed in the second zone.

The cooler may then be exposed to an environment surrounding the cooler having a temperature of 75° Fahrenheit and thereby result in a flow of heat from the environment and into the cooler. In response to the heat flow, the four PCM modules absorb the heat and a portion of each of the four PCM modules undergo a solid to liquid phase change and thereby maintains the temperature within the first zone at 5° Fahrenheit. Similarly, in response to the heat flow, the fifth PCM module absorbs the heat and a portion of the fifth PCM module undergoes a solid to liquid phase change and thereby maintains the temperature within the second zone at 40° Fahrenheit.

Example 3

A caterer may desire to transport chilled potato salad that needs to be maintained at 33° Fahrenheit and hot beans that need to be maintained at 80° Fahrenheit. Based on the thermal information of the potato salad and beans, a cooler including two zones of temperature regulation may be required. To generate the two zones, a thermally insulated divider may be placed in the cooler thereby forming a first zone and a second zone.

Based on the thermal information of the potato salad, e.g., 33° Fahrenheit, PCM modules having a solid-liquid phase change temperature of 33° Fahrenheit may be selected. The PCM modules are chilled to less than 33° Fahrenheit. The PCM modules undergo liquid to solid phase transitions in response to being chilled.

Once chilled, the potato salad and the PCM modules are placed in the first zone. The beans are placed in the second zone.

The cooler may then be exposed to an environment surrounding the cooler having a temperature of 60° Fahrenheit and thereby result in a flow of heat from the environment and into the first zone of the cooler. In response to the heat flow, the PCM modules absorb the heat and a portion of each of the PCM modules undergo a solid to liquid phase change and thereby maintains the temperature within the first zone at 33° Fahrenheit. The beans are maintained near 80° Fahrenheit by virtue of the insulation provided by the cooler and the thermally insulated divider.

One or more embodiments of the invention may provide one or more of the following advantages: i) a cooler in accordance with embodiments of the invention may regulate a temperature of a good for a longer period of time than by a cooler that utilizes ice for cooling, ii) a cooler in accordance with embodiments of the invention may enable a first type of goods and a second type of goods to be regulated at different temperatures, iii) a cooler in accordance with embodiments of the invention may regulate a temperature of a good to a desired range for a desired period of time of, for example, five days, iv) a cooler in accordance with embodiments of the invention may be configurable to enable goods to be regulated at temperatures between 5° to 55° Fahrenheit, v) a cooler in accordance with embodiments of the invention may be reusable, e.g., no component of the cooler is used up or otherwise lost during use of the cooler, and vi) a cooler in accordance with embodiments of the invention may be capable of maintaining goods at a temperature of less than 40° Fahrenheit for up to four days utilizing a PCM module having a solid to liquid phase transition temperature of 33° Fahrenheit.

While the invention has been described above with respect to a limited number of embodiments, those skilled in the art, having the benefit of this disclosure, will appreciate that other embodiments can be devised which do not depart from the scope of the invention as disclosed herein. Accordingly, the scope of the invention should be limited only by the attached claims. 

What is claimed is:
 1. A cooler, comprising: a body; a divider configured to divide an interior of the body into a first zone and a second zone; a first phase change material (PCM) module disposed in the first zone; and a second PCM module disposed in the second zone.
 2. The cooler of claim 1, wherein the first PCM module has a solid to liquid phase transition temperature that is different from a solid to liquid phase transition temperature of the second PCM module.
 3. The cooler of claim 1, wherein the first PCM module has a solid to liquid phase transition temperature that is below freezing.
 4. The cooler of claim 1, wherein the second PCM module has a solid to liquid phase transition temperature that is above freezing.
 5. The cooler of claim 1, wherein the body comprises a hollow rectangular prism having an open side.
 6. The cooler of claim 1, wherein the body comprises polyurethane foam.
 7. The cooler of claim 6, wherein the polyurethane foam is encapsulated by a layer of linear low-density polyethylene.
 8. The cooler of claim 1, wherein the divider comprises a panel having a shape complementary to a portion of the shape of the interior of the body.
 9. The cooler of claim 1, wherein the divider comprises polyurethane foam.
 10. The cooler of claim 1, wherein the first PCM modules comprises: a plastic housing; and a phase change material, disposed within the plastic housing, having a solid to liquid phase change temperature.
 11. The cooler of claim 10, wherein the solid to liquid phase change temperature is set based on a regulation temperature of goods to be disposed in the first zone.
 12. The cooler of claim 10, wherein the plastic housing comprises high density polyethylene.
 13. The cooler of claim 10, wherein the phase change material comprises a solution of salt water.
 14. The cooler of claim 1, where the second PCM modules comprises: a plastic housing; and a phase change material, disposed within the plastic housing, having a solid to liquid phase change temperature.
 15. The cooler of claim 14, wherein the solid to liquid phase change temperature is set based on a regulation temperature of goods to be disposed in the second zone.
 16. The cooler of claim 14, wherein the plastic housing comprises high density polyethylene.
 17. The cooler of claim 14, wherein the phase change material comprises a solution of salt water.
 18. The cooler of claim 1, further comprising: a second divider, wherein the second divider is configured to divide the second zone into a third zone and a fourth zone.
 19. The cooler of claim 18, further comprising: a third PCM module disposed in the fourth zone.
 20. A method of assembling a cooler, comprising: obtaining thermal information of goods to be disposed in the cooler; determining, based on at least in part the thermal information, a quantity of zones; determining, based on at least in part the thermal information of a portion of the goods to be disposed in a first zone of the quantity of zones, a type and a quantity of phase change material (PCM) modules; dividing, based on the quantity of zones, the cooler into the quantity of zones by inserting dividers; loading, based on portion of the goods to be disposed in the first zone and the quantity and type of PCM modules, the portion of the goods and the quantity and the type of PCM modules into the first zone.
 21. The method of claim 20, further comprising: determining, based on at least in part the thermal information of a second portion of the goods to be disposed in a second zone of the quantity of zones, a second type and a second quantity of phase change material (PCM) modules; loading, based on portion of the goods to be disposed in the second zone and the second quantity and second type of PCM modules, the second portion of the goods and the second quantity and the second type of PCM modules into the second zone.
 22. A cooler, comprising: a body; a first divider, comprising a first phase change material (PCM) module, configured to divide an interior of the body into a first zone and a second zone; and a second PCM module disposed in the second zone.
 23. The cooler of claim 22, wherein the first PCM module has a solid to liquid phase transition temperature that is different from a solid to liquid phase transition temperature of the second PCM module.
 24. The cooler of claim 22, wherein the first PCM module has a solid to liquid phase transition temperature that is below freezing.
 25. The cooler of claim 22, wherein the second PCM module has a solid to liquid phase transition temperature that is above freezing.
 26. The cooler of claim 22, wherein the divider further comprises a panel having a shape complementary to a portion of the shape of the interior of the body.
 27. The cooler of claim 22, wherein the divider further comprises a thermally insulated layer.
 28. The cooler of claim 27, wherein the first PCM module is separated from the second zone by the thermally insulated layer when the first divider is disposed in the cooler. 